Service Manual

Quiet Diesel Generator Set

HDZAA (Spec A−B)

English − Original Instructions 6−2010 983−0502 (Issue 8)

 California
Proposition 65 Warning
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.

diesel warnings
Table of Contents

SECTION PAGE

SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
About this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How to Obtain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Engine Emissions Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Typical Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
2. OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Recommended Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Recommended Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Starting Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Remote Operator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Loading the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Resetting Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Connecting to Utility Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Operating in Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Operating in Hot Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Operating at High Altitude . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Operating in Dusty Environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Breaking In a New Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Exercising the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Storing the Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
3. PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Maintaining the Battery and Battery Connections . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

i
SECTION PAGE

Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Cleaning the Engine Oil Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Replacing the Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Cleaning the Spark Arrestor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Replacing the Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
4. SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Removing Generator Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Removing Outer Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Inverter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Internal Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
DC Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Removing Engine/PMA Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
PMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Torque specifications: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Maintenance Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Symptom Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Load on engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
7. SERVICE CHECKLIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

ii
SAFETY PRECAUTIONS
Thoroughly read the OPERATOR’S MANUAL  Engine cooling air must not be used for heat-
before operating the generator set. Safe op- ing the vehicle.
eration and top performance can only be ob-
tained when equipment is properly operated GENERATOR VOLTAGE IS DEADLY
and maintained.
 Disable the automatic genset feature (AGS)
of an inverter−charger or other automatic
The following symbols in this manual alert you to starting device before servicing the genset to
potential hazards to the operator, service person avoid electric shock from an unexpected
and equipment. start.
DANGER alerts you to an immediate hazard  Generator electrical output connections must
that will result in severe personal injury or be made by a trained and experienced elec-
death. trician in accordance with applicable codes.
 The generator set must not be connected to
WARNING alerts you to a hazard or unsafe shore power (utility). Back-feed to shore pow-
practice that can result in severe personal in- er can cause electrocution and damage to
jury or death. equipment. An approved switching device
must be used to prevent interconnections.
CAUTION alerts you to a hazard or unsafe  Use caution when working on live electrical
practice that can result in personal injury or equipment. Remove jewelry, make sure
equipment damage. clothing and shoes are dry, stand on a dry
wooden platform or rubber insulating mat and
When equipped with an integral or add−on Auto- use tools with insulated handles.
matic Generator Starting System (AGS) control,
exhaust carbon monoxide (CO), electric shock, DIESEL FUEL IS COMBUSTIBLE
and moving parts hazards are possible due to un-
 Do not smoke or turn electrical switches ON
expected starting. Turn off AGS whenever per-
or OFF where fuel fumes are present or in
forming maintenance or service, when the vehicle
areas sharing ventilation with fuel tanks or
is stored between uses, is awaiting service, or is
equipment. Keep flames, sparks, pilot lights,
parked in a garage or other confined area.
arc-producing equipment and all other
sources of ignition well away.
ENGINE EXHAUST IS DEADLY
 Fuel lines must be secured, free of leaks and
 Inspect for exhaust leaks at every startup and separated or shielded from electrical wiring.
after every eight hours of running.
 Learn the symptoms of carbon monoxide poi- MOVING PARTS CAN CAUSE SEVERE
soning in the generator set Operator’s Manu- PERSONAL INJURY OR DEATH
al.  Disable the automatic genset starting feature
 Never sleep in the vehicle while the generator (AGS) of an inverter−charger or other auto-
set is running unless the vehicle is equipped matic starting device before servicing the
with a working carbon monoxide detector. genset to avoid unexpected starting.

 Do not operate the generator set when the  Do not wear loose clothing or jewelry near
vehicle is parked in a confined space, such as moving parts such as fans and other moving
a garage. parts.
 Keep hands away from moving parts.
 The exhaust system must be installed in ac-
cordance with the generator set Installation  Keep guards in place over fans and other
Manual. moving parts.

iii
 BATTERY GAS IS EXPLOSIVE the batteries to prevent starting during main-
tenance and service. (Always disconnect
 Wear safety glasses.
negative [−] first and reconnect last to prevent
 Do not smoke. sparks between tools and vehicle frame.)
 To reduce arcing when disconnecting or re-  Keep the generator set and its compartment
connecting battery cables, always discon- clean. Excess oil and oily rags can catch fire.
nect the negative (−) battery cable first and Dirt and gear stowed in the compartment can
reconnect it last. restrict cooling air.
FLAMMABLE VAPORS CAN BE IGNITED  Make sure all fasteners are secure and
BY OPERATION OF COACH ELECTRICAL torqued properly.
SYSTEMS AND CAUSE DIESEL ENGINES  Do not work on the generator set when men-
TO OVERSPEED tally or physically fatigued or after consuming
 Stop the generator set before fueling the alcohol or drugs.
coach to reduce the risk of igniting flammable  You must be trained and experienced to
vapors. make adjustments while the generator set is
 Do not operate the diesel-powered generator running—hot, moving or electrically live parts
set where there are or can be flammable va- can cause severe personal injury or death.
pors created by fuel spills, gas leaks, etc.  Used engine oil has been identified by some
Flammable vapors drawn into a diesel engine U. S. state and federal agencies as causing
air intake system can cause the engine to cancer or reproductive toxicity. Do not ingest,
overspeed, which can result in fire, explosion inhale, or contact used oil or its vapors.
and equipment damage. The owners and op-
erators of the generator set are solely respon-  Keep multi-class ABC fire extinguishers
sible for safe operation. readily at hand. Class A fires involve ordinary
combustible materials such as wood and
GENERAL PRECAUTIONS cloth. Class B fires involve combustible and
flammable liquids and gaseous fuels.
 Keep children away from the generator set. Class C fires involve live electrical equip-
 Do not use evaporative starting fluids. They ment. See NFPA No. 10 (Portable Fire Extin-
are highly explosive. guishers) or equivalent—BS EN 3-7:2004.
 To prevent accidental or remote starting while  Generator set installation and operation must
working on the generator set, press the Stop comply with all applicable local, state and fed-
button and disconnect the battery cables at eral codes and regulations.

iv
1. Introduction
ABOUT THIS MANUAL

This is the Service Manual for the generator sets

listed on the front cover.

WARNING This generator set is not a life sup-

port system. It can stop without warning. Chil-
dren, persons with physical or mental limita-
tions, and pets could suffer personal injury or
death. A personal attendant, redundant power
or alarm system must be used if generator set
operation is critical.

WARNING Improper service or replacement of

parts can lead to severe personal injury or death
and damage to equipment and property. Service
personnel must be qualified to perform electri-
cal and mechanical service.

Unauthorized modifications or replacement of

fuel, exhaust, air intake or speed control system
components that affect engine emissions are
prohibited by law in the State of California.

NAMEPLATE

Be ready to provide the generator set model and se-

rial numbers on the nameplate when contacting
Cummins Onan for parts, service or information.
Figure 1-1 illustrates typical model and serial num- FIGURE 1-1. TYPICAL NAMEPLATE
bers.

1-1
 ENGINE EMISSIONS COMPLIANCE
The label that states compliance with applicable en-
gine emissions regulations is located on the air
cleaner cover as shown circled in Figure 1-2. Refer
also to the FEDERAL EMISSION DESIGN AND
DEFECT LIMITED WARRANTY FOR C. I. EN-
GINES (DIESELS) that was shipped in the same
package as the Operator’s Manual.

FIGURE 1-2. EMISSIONS LABEL LOCATION

1-2
 TYPICAL GENERATOR SET
Figure 1-3 illustrates a typical generator set show-
ing connection points and maintenance access.

GENERATOR SET AC OUTPUT, BATTERY POS (+)

STOP SWITCH & REMOTE CONTROL
INTERNAL CONNECTIONS
MUFFLER
SERVICE COOLING &
ACCESS VENTILATING
AIR INLET

BATTERY NEG (−)

CONNECTION
MAINTENANCE ACCESS
(AIR, FUEL & OIL FILTERS)
CHASSIS
GROUND
BOTTOM EXHAUST & BOTTOM FUEL
HOT AIR DISCHARGE OIL DRAIN CONNECTIONS

FIGURE 1-3. TYPICAL GENERATOR SET

1-3
THIS PAGE LEFT INTENTIONALLY BLANK

1-4
2. Operation
RECOMMENDED FUEL RECOMMENDED ENGINE OIL
Use API (American Petroleum Institute) perfor-
mance Class CF engine oil or better. Also look for
WARNING Diesel fuel is combustible and can the SAE (Society of Automotive Engineers) viscos-
cause severe personal injury or death. Do not ity grade. Referring to Figure 2-1, choose the vis-
smoke near fuel tanks or fuel-burning equip- cosity grade appropriate for the ambient tempera-
ment or in areas sharing ventilation with such tures expected until the next scheduled oil change.
equipment. Keep flames, sparks, pilot flames, Multi-grade oils such as SAE 15W-40 are recom-
electrical arcs and switches and all other mended for year-round use.
sources of ignition well away. Keep a multi- See Section 6. Specifications for oil capacity.
class ABC fire extinguisher handy.
STARTING BATTERIES
The generator set requires a 12 volt battery to power
High quality Grade 2-D diesel fuel is necessary for its control and starting circuits. Reliable generator
good performance and long engine life. Diesel fuels set starting and starter service life depend upon ad-
specified by ASTM D975 or EN 590 are recom- equate battery system capacity and maintenance.
mended. Use Grade 1-D diesel fuel when ambient
See MAINTAINING THE BATTERY AND BATTERY
temperatures are below freezing. The fuel should
CONNECTIONS (p. 3-2) and Section 6. Specifica-
have a Cetane number of at least 45 for reliable tions for minimum battery ratings.
starting.

Note: Ultra Low Sulfur Diesel (ULSD) fuel that meets

the ASTM D975 standard for lubricity is suitable for
use with this generator set. The 1 to 2 percent less
energy content of the fuel can have a slight effect on
maximum engine power.

Note: B5 Bio-Diesel fuel that meets industry specifi-

cations and quality is suitable for use with this gener-
ator set. FIGURE 2-1. OIL VISCOSITY VS. TEMPERATURE

2-1
 STOP SWITCH must stay in its “1” position for the generator set to
run.
Press the stop switch (Figure 2-2) to stop the gener-
ator set or to prevent it from starting while perform- Note: This is not a start switch. The generator set can
ing maintenance and service. To allow the genera- only be started using the remote operator panel
tor set to run, press the switch again. The switch (p. 2-3).

FIGURE 2-2. STOP SWITCH

2-2
 REMOTE OPERATOR PANEL START Button − To start the generator set, press
and hold this button when “GEN OFF” appears on
The remote operator panel (Figure 2-3) has the fol- the display screen after having pressed the Display
lowing features: ON button.

Display ON / Gen OFF Button − Press this button Display Screen − The display screen displays gen-
to wake the generator set and display screen prior to erator set status, battery voltage, hours run and
pressing the START button. This also starts the fuel warning and shutdown messages (see Section 5.
pump, which will prime the fuel system for five min- Troubleshooting).
utes if the generator set does not start.
Low Oil Indicator Light − This light warns that en-
Press this button to stop the generator set. gine oil pressure is low or temperature is too high.

FIGURE 2-3. OPERATOR PANEL

2-3
 WARNING EXHAUST GAS is deadly. All en- remove any objects blocking the air inlet or air
gine exhaust contains carbon monoxide; an outlet.
odorless, colorless, poisonous gas that can 4. Turn off air conditioners and other large ap-
cause unconsciousness and death. Symptoms pliances.
of carbon monoxide poisoning include:
 Dizziness  Headache STARTING
 Nausea  Weakness and Sleepiness
 Vomiting  Inability to Think Coherently
1. Perform the PRE-START CHECKS.
IF YOU EXPERIENCE ANY OF THESE SYMP-
TOMS, GET INTO FRESH AIR IMMEDIATELY. If 2. Start the generator set at the remote operator
symptoms persist, seek medical attention. Shut panel.
down the generator set and do not operate it un- A. Press and release the Display ON button.
til it has been inspected and repaired.
B. Wait for “GEN OFF” to appear. If the gen-
Never sleep in the vehicle while the generator erator set ran out of fuel and it is necessary
set is running unless the vehicle has a working to prime the fuel system, wait at least one
carbon monoxide detector. The exhaust system minute before pressing the START button
must be installed in accordance with the gener- to allow the fuel pump to prime fuel.
ator set Installation Manual. Make sure there is
ample fresh air when operating the generator C. Press and hold the START button until the
set in a confined area. generator set starts. The generator set will
make up to three attempts to start. “GEN
PRE-START CHECKS ON” will appear on the display screen
when the generator set starts. “GEN
Before the first start of the day and after every eight WAIT” will appear during rest periods be-
hours of operation, inspect the generator set as tween start attempts.
instructed under GENERAL INSPECTION (p. 3-2). 3. Press the GEN OFF button to reset the control
Keep a log of maintenance and the hours run and if the generator set does not start after three at-
perform any maintenance that may be due. See Re- tempts. See Section 5. Troubleshooting if the
turning the Generator Set to Service (p. 2-7) if the generator set still does not start.
vehicle has been in storage.
4. Let the generator set warm up a few minutes
Before each start: until it is running smoothly before connecting
1. Make sure all vehicle carbon monoxide (CO) the vehicle electrical loads (appliances).
detectors are working. 5. Check for fuel, oil and exhaust leaks. Stop the
2. Check for fuel and oil leaks and damage to the generator set immediately if there is leak and
exhaust system. have it repaired.

3. To prevent overheating and to reduce fouling STOPPING

with dust and debris, make sure the generator
set’s normal ground clearance is not being re- Run the generator set under no load for a few min-
duced by sloping ground, curbs, logs or other utes to allow the engine to cool down and then press
objects. Repark the vehicle if necessary and/or and release the Gen OFF button.

2-4
 LOADING THE GENERATOR SET TABLE 2-1. TYPICAL APPLIANCE LOADS
Appliance Load (watts)
Air Conditioner 1400-2000
The generator set can power AC motors, air condi-
Battery Charger Up to 3600
tioners, AC/DC converters, battery chargers and
other appliances. How much appliance load* can be DC Converter 300-900
powered depends upon the generator set power rat- Refrigerator 600-1000
ing. The generator set will shut down if the sum of Microwave Oven 1000-1500
the loads exceeds generator set power. See Sec- Electric Frying Pan or Wok 1000-1500
tion 5. Troubleshooting. Electric Stove Element 350-1000
Electric Water Heater 1000-1500
To avoid overloading the generator set and causing Electric Iron 500-1200
shutdowns, compare the sum of the loads of the ap- Electric Hair Dryer 800-1500
pliances that are likely to be used at the same time to Coffee Percolator 550-750
the power rating of the generator set. It may be nec-
Television 200-600
essary to run fewer appliances at the same
time—the sum of the loads must not be greater Radio 50-200
than generator set rating. Electric Drill 250-750
Electric Broom 200-500
Electric Blanket 50-200
The generator set may shut down due to overload
when a large motor or air conditioner is started or
cycles off and then on again, even though the sum of Maximum power decreases as altitude increases
the loads is less than generator set rating. The rea- because air density decreases. For every 1000-foot
son for this is that a motor’s startup load is much (305 m) increase in elevation you can expect power
larger than its running load. It may be necessary to to decrease approximately 3.5 percent. It may be
run fewer appliances when large motors and air necessary to run fewer appliances at higher alti-
conditioners are cycling on and off. tudes.

TABLE 2-2. POWER VS. ALTITUDE

Altitude
Maximum Power
(Elevation above Sea Level)
at/below 500 ft (152 m) 3200 W (rated)
at 2500 ft (762 m) 2980 W
at 5500 ft (1676 m) 2640 W
above 5500 ft (1676 m) 2640 W minus 112 W every 1000 ft (305 m)

* Appliance load and generator set power are measured in terms of watts (W) or kilowatts (kW), where 1 kilowatt (kW) = 1000 watts (W).

2-5
 RESETTING CIRCUIT BREAKERS OPERATING IN COLD WEATHER
Note: The generator set does not have a power out- Make sure the engine oil viscosity is appropriate for
put circuit breaker.
the cold ambient temperatures. See ENGINE OIL
If a circuit breaker in the main power distribution RECOMMENDATIONS (p. 2-1). Be sure to
panel of the vehicle trips, either a circuit shorted or change the oil if a sudden drop in temperature oc-
too many appliances were running. curs.

If a circuit breaker trips, disconnect or turn off as OPERATING IN HOT WEATHER

many loads as possible and reset the circuit break-
er. (Push the circuit breaker to OFF to reset it and Pay particular attention to the following items when
then to ON to reconnect the circuit.) If the circuit operating the generator set in hot weather:
breaker trips right away, either the electrical dis-
tribution system has a short or the circuit breaker is 1. Make sure nothing blocks airflow to and from
faulty. Call a qualified electrician. the generator set.
2. Make sure the engine oil viscosity is appropri-
If the circuit breaker does not trip right away, recon-
ate for the hot ambient temperatures. See EN-
nect the appliances, one by one, up to a total load
GINE OIL RECOMMENDATIONS (p. 2-1).
that does not overload the generator set.
3. Keep the generator set clean.
Electrical appliances and tools must be used and
maintained properly and be properly grounded to 4. Perform maintenance due. See PERIODIC
cause the line circuit breakers to trip when short cir- MAINTENANCE SCHEDULE (p. 3-1).
cuits occur.
OPERATING AT HIGH ALTITUDE
WARNING Short circuits in electrical ap-
pliances and tools can cause fire and electrical For the effect of altitude on maximum power, see
shock leading to severe personal injury or LOADING THE GENERATOR SET (p. 2-5).
death. Read and follow the equipment and tool
manufacturer’s instructions and warnings re- OPERATING IN DUSTY ENVIRONMENTS
garding use, maintenance and proper ground-
ing. Pay particular attention to the following items when
operating the generator set in dusty environments:
CONNECTING TO UTILITY POWER
1. Do not let dirt and debris accumulate inside the
A vehicle with provisions for connecting utility power generator set compartment. Keep the genera-
must have an approved device to keep the genera- tor set clean.
tor set and utility from being interconnected. See the
generator set Installation Manual for more informa- 2. Perform air cleaner maintenance more often.
tion. See PERIODIC MAINTENANCE SCHEDULE
(p. 3-1).
WARNING Interconnecting the generator set
3. Change engine oil more often. See PERIODIC
and the public utility can lead to electrocution of
MAINTENANCE SCHEDULE (p. 3-1).
utility line workers, equipment damage and fire.
Use an approved switching device to prevent in- 4. Keep containers of engine oil that have been
terconnections. opened tightly closed to keep out dust.

2-6
 BREAKING IN A NEW ENGINE ator set cannot be exercised regularly and will be
idle for more than 120 days.
Proper engine break-in on a new generator set or on
one with a rebuilt engine is essential for top engine Storing the Generator Set
performance and acceptable oil consumption. Do 1. Change the engine oil and attach a tag indicat-
not exceed 70 percent of rated power during the first ing oil viscosity. See ENGINE OIL REC-
50 hours of operation. See LOADING THE GEN- OMMENDATIONS (p. 2-1).
ERATOR SET (p. 2-5).
2. Disconnect the battery cables (negative [−]
Proper engine oil and oil level are especially critical cable first) from the starting battery and store
during break-in because of the higher engine tem- the battery according to the battery manufac-
peratures that can be expected. Change the oil if not turer’s recommendations. See MAINTAINING
appropriate for the ambient temperatures during THE BATTERY AND BATTERY CONNEC-
break-in. See ENGINE OIL RECOMMENDATIONS TIONS (p. 3-2).
(p. 2-1). Change the oil after the first 50 hours of 3. Plug the exhaust tail pipe to keep out dirt, mois-
operation. ture, bugs, etc.
4. Close the fuel supply valve (if so equipped).
EXERCISING THE GENERATOR SET
Returning the Generator Set to Service
Exercise the generator set at least 2 hours each
month if use is infrequent. Run the generator set at 1. Check the oil tag on the generator set and
approximately 1/2 rated power. See LOADING THE change the oil if the viscosity indicated is not
GENERATOR SET (p. 2-5). A single two hour ex- appropriate for the temperatures expected.
ercise period is better than several shorter periods. See ENGINE OIL RECOMMENDATIONS
(p. 2-1).
Exercising a generator set drives off moisture, re-lu- 2. Reconnect the starting battery (negative [−]
bricates the engine, replaces stale fuel and re- cable last). See MAINTAINING THE BATTERY
moves oxides from electrical contacts. The result is AND BATTERY CONNECTIONS (p. 3-2).
better starting, more reliable operation and longer
engine life. 3. Remove the plug from the exhaust tailpipe.
4. Change the air filter element if it is dirty (p. 3-6).
STORING THE GENERATOR SET
5. Open the fuel supply valve (if so equipped).
Proper storage is essential for preserving top gener- 6. Inspect the generator set. See GENERAL IN-
ator set performance and reliability when the gener- SPECTION (p. 3-2).

2-7
THIS PAGE LEFT INTENTIONALLY BLANK

2-8
3. Periodic Maintenance
Periodic maintenance is essential for top perfor- ever, warranty work must be completed by an au-
mance and long generator set life. Use Table 3-1 as thorized Cummins Onan dealer.
a guide for normal periodic maintenance. In hot and
dusty environments some maintenance procedures WARNING Accidental or remote starting can
should be performed more frequently, as indicated cause severe personal injury or death. Push the
by the footnotes in the table. Stop Switch Off and disconnect the battery
cables at the batteries to prevent starting during
Maintenance, replacement or repair of emission maintenance and service. (Always disconnect
control devices and systems may be performed by negative [−] first and reconnect last to prevent
any engine repair establishment or individual. How- sparks between tools and vehicle frame.)

TABLE 3-1. PERIODIC MAINTENANCE SCHEDULE

FREQUENCY
MAINTENANCE TASK After First Every Every Every Every Every
Page
20 Hrs 8 Hrs Month 250 Hrs 500 Hrs 1000 Hrs

General Inspection  3-2

Check Engine Oil Level  3-3
Check Battery & Battery Connections1  3-2
Change Engine Oil1, 2, 3   3-4
Clean Spark Arrestor3  3-7
Replace Engine Air Filter2, 3  3-6
Replace Fuel Filter3  3-8
Adjust Engine Valve Lash4  4-6
Clean the Oil Filter  3-5
Check Fuel Injector Pressure4, 5  4-6
1. Perform more often when operating in hot weather.
2. Perform more often when operating in dusty conditions.
3. Perform at least once a year.
4. Must be performed by trained and experienced personnel (authorized Cummins Onan service representatives).
5. EPA requirement.

3-1
 GENERAL INSPECTION the fuel line is not rubbing against other parts. Re-
place worn or damaged fuel line parts before leaks
Inspect the generator set before the first start of the occur.
day and after every eight hours of operation.
WARNING Diesel fuel leaks can lead to fire. Do
Oil Level not operate the generator set if operation
causes fuel to leak.
Check engine oil level (Figure 3-1).
Mechanical
Exhaust System
Look for mechanical damage and listen for unusual
WARNING EXHAUST GAS IS DEADLY! Do not noises. Check the generator set mounting bolts.
operate the generator set if there is an exhaust
leak or any danger of exhaust gases entering or To prevent overheating and to reduce fouling with
being drawn into the vehicle. dust and debris, make sure the generator set’s nor-
mal ground clearance is not being reduced by slop-
Look and listen for exhaust system leaks while the ing ground, curbs, logs or other objects. Repark the
generator set is running. Shut down the generator vehicle if necessary and/or remove any objects
set if a leak is found and have it repaired before op- blocking the air inlet or air outlet.
erating the generator set again.
MAINTAINING THE BATTERY AND
Look for openings or holes between the generator BATTERY CONNECTIONS
set compartment and vehicle cab or living space if
the generator set engine sounds louder than usual. WARNING Flames, sparks and arcing at bat-
Have all such openings or holes closed off or sealed tery terminals, light switches and other equip-
to prevent exhaust gases from entering the vehicle. ment can ignite battery gas causing severe per-
sonal injury—Ventilate battery area before
Replace dented, bent or severely rusted sections of working on or near battery—Wear safety
the tailpipe and make sure the tailpipe extends at glasses—Do not smoke—Switch work light ON
least 1 inch (25.4 mm) beyond the perimeter of the or OFF away from battery—Stop generator set
vehicle. and disconnect charger before disconnecting
battery cables—Disconnect negative (−) cable
WARNING Do not park the vehicle in high grass first and reconnect last.
or brush. Contact with the exhaust system can
cause a fire. Refer to Table 3-1 for scheduled battery mainte-
nance and follow the battery manufacturer’s in-
Park the vehicle so that the generator set exhaust structions. If battery (DC) voltage is consistently low
gases can disperse away from the vehicle. Barriers or high, have the vehicle battery charging system
such as walls, snow banks, high grass and brush serviced. (The generator set does not recharge the
and other vehicles can cause exhaust gases to ac- battery.) Always:
cumulate in and around the vehicle. 1. Keep the battery case and terminals clean and
dry and the terminals tight.
Do not operate power ventilators or exhaust fans
while the vehicle is standing with the generator set 2. Use a battery terminal puller to remove the
running. The ventilator or fan can draw exhaust cable clamps on post-type battery terminals.
gases into the vehicle. 3. Tighten threaded-stud battery terminals as rec-
ommended by the battery manufacturer.
Fuel System
4. Make sure which terminal is positive (+) and
Check for leaks at hose, tube and pipe fittings in the which is negative (−) before making battery
fuel supply system while the generator set is run- connections, always removing the negative (−)
ning and while it is stopped. Check flexible fuel hose cable first and reconnecting it last to reduce
sections for cuts, cracks, and abrasions. Make sure arcing.

3-2
 CHECKING ENGINE OIL LEVEL 2. Pull out the oil dip stick, wipe it clean, reinsert
it and pull it out again to check the oil level (Fig-
WARNING State and federal agencies have de- ure 3-1).
termined that contact with used engine oil can 3. Add or drain oil as necessary. See REC-
cause cancer or reproductive toxicity. Avoid OMMENDED ENGINE OIL (p. 2-1). Keep the
skin contact and breathing of vapors. Use rub- oil level between the MIN / MAX marks.
ber gloves and wash exposed skin. CAUTION Too much oil can cause high oil
consumption. Too little oil can cause severe
To check engine oil level: engine damage. Keep the oil level between
1. Park the vehicle on level ground, shut down the the MIN / MAX marks.
generator set and remove the front access 4. Reinsert the dipstick and secure the oil fill cap
door. and front access door.

FIGURE 3-1. CHECKING ENGINE OIL LEVEL

3-3
 CHANGING ENGINE OIL 1. Place a pail under the oil drain plug (Fig-
ure 3-2).
WARNING Accidental or remote starting can 2. Remove the maintenance access door and the
cause severe personal injury or death. Push the oil fill cap, unscrew the oil drain cap and drain
Stop Switch Off and disconnect the battery all the oil from the engine. Reinstall the oil
cables at the batteries to prevent starting during drain cap securely.
maintenance and service. (Always disconnect 3. Refill with approximately 0.7 quarts of oil, check
negative [−] first and reconnect last to prevent oil level (Figure 3-1) and secure the front ac-
sparks between tools and vehicle frame.) cess door.

Refer to Table 3-1 for scheduled engine oil change. 4. Dispose of the used oil according to local envi-
Change oil more often in hot and dusty environ- ronmental regulations.
ments. To change engine oil: 5. Secure the front access door.

FIGURE 3-2. CHANGING ENGINE OIL

3-4
 CLEANING THE ENGINE OIL STRAINER cessible through the front access door (Figure 3-3).
To replace the oil strainer:
WARNING Accidental or remote starting can
1. Remove the maintenance access door.
cause severe personal injury or death. Push the
Stop Switch Off and disconnect the battery 2. Loosen the center screw of the strainer (about
cables at the batteries to prevent starting during five turns) and withdraw the strainer from the
maintenance and service. (Always disconnect engine block.
negative [−] first and reconnect last to prevent
sparks between tools and vehicle frame.) 3. Use compressed air to clean the strainer. Blow
the debris from inside out.
WARNING Wear safety glasses when using 4. Replace the O-rings or strainer if damaged.
compressed air to clean the oil strainer to pro-
tect your eyes from severe injury from flying de- 5. Lubricate the O-rings with clean oil and insert
bris. the strainer until it stops.
6. Check for spring tension against the strainer
Refer to Table 3-1 for scheduled cleaning of the en-
and tighten the center screw.
gine oil strainer. Clean the oil strainer more often in
hot and dusty environments. The oil strainer is ac- 7. Secure the front access door.

FIGURE 3-3. CLEANING ENGINE OIL STRAINER

3-5
 REPLACING THE AIR FILTER ELEMENT ment. Replace it more often in dusty environments.
The air filter is accessible through the front access
WARNING Accidental or remote starting can
door (Figure 3-4). To replace the air filter:
cause severe personal injury or death. Push the
Stop Switch Off and disconnect the battery 1. Remove the filter cover
cables at the batteries to prevent starting during 2. Unscrew the the knurled nut and remove the
maintenance and service. (Always disconnect old filter element.
negative [−] first and reconnect last to prevent
sparks between tools and vehicle frame.) 3. Clean dust and debris from the filter housing
and install the new filter element.
Refer to Table 3-1 for scheduled air filter replace- 4. Secure the front access door.

FIGURE 3-4. REPLACING THE AIR FILTER ELEMENT

3-6
 CLEANING THE SPARK ARRESTOR To clean the in-line tailpipe spark arrestor:

Refer to Table 3-1 for scheduled cleaning of the in- 1. Remove the cleanout plug on the side of the
line tail pipe spark arrestor canister (Figure 3-5), spark arrestor canister.
which meets U.S. Forest Service requirements.
Cleaning is required for maximum generator set 2. Start the generator set and load it nearly to full
performance. power. Let the generator set run for about five
minutes to expel the soot.
WARNING A hot muffler can cause severe
burns. Let the muffler cool down before remov- 3. Stop the generator set, allow the muffler to cool
ing or installing the cleanout plug. down, and reinstall the cleanout plug.

FIGURE 3-5. TYPICAL LOCATION OF SPARK ARRESTOR IN TAILPIPE

3-7
 REPLACING THE FUEL FILTER Dirt can damage the fuel system.
CAUTION
Make sure to wipe dirt off the fuel hose fittings
See Table 3-1 for scheduled fuel filter replacement. before disconnecting.
A dirty fuel filter may be the cause of a failure to start.

WARNING Diesel fuel is combustible and can The fuel filter is accessible through the front access
cause severe personal injury or death. Do not door (Figure 3-6). To replace the fuel filter:
smoke near diesel fuel tanks or equipment. 1. Have paper towels or rags ready to clean the
Keep flames, sparks, pilot lights, electrical two fuel hose fittings and absorb any fuel that
switches, arc-producing equipment and all oth- spills.
er sources of ignition well away. Have a type
ABC fire extinguisher ready to use. 2. Clean the two fuel hose fittings to keep dirt from
entering the fuel hoses.
Close any fuel line shutoff valve before discon-
necting the fuel line from the filter. 3. Loosen the two fuel hose clamps and the filter
body clamp and replace the filter element.
WARNING Accidental or remote starting can Make sure the arrow on the filter element points
cause severe personal injury or death. Push the up in the direction of fuel flow.
Stop Switch Off and disconnect the battery 4. Dispose of the fuel filter and paper towels or
cables at the batteries to prevent starting during rags in accordance with local environmental
maintenance and service. (Always disconnect regulations.
negative [−] first and reconnect last to prevent
sparks between tools and vehicle frame.) 5. Secure the front access door.

FIGURE 3-6. FUEL FILTER

3-8
4. Service
REMOVING GENERATOR SET 4. Disconnect the exhaust tailpipe from the muf-
fler flange.
See Section 5. Troubleshooting to determine the
probable cause of the problem before removing the 5. Disconnect the supply and return fuel lines from
generator set for service. The generator set is nor- the generator set.
mally mounted on a supporting frame. Contact the
vehicle manufacturer or installer if the best way to Removal from Vehicle
remove the generator set is not obvious.
Make sure that the generator set is firmly supported
WARNING Accidental or remote starting can before loosening any mounting bolts (Figure 4-1).
cause severe personal injury or death. Push the
Stop Switch Off and disconnect the battery Generator sets are heavy and can
WARNING
cables at the batteries to prevent starting during cause severe personal injury if dropped during
maintenance and service. (Always disconnect removal. Use adequate lifting devices. Keep
negative [−] first and reconnect last to prevent hands and feet clear while lifting.
sparks between tools and vehicle frame.)
Installation in Vehicle
WARNING Diesel fuel is combustible and can
cause severe personal injury or death. Do not
Generally, installation is the reverse of removal and
smoke near fuel tanks or fuel-burning equip-
disconnection. Before installing the generator set,
ment or in areas sharing ventilation with such
repair any damage to and seal all holes in the vapor-
equipment. Keep flames, sparks, pilot flames,
tight, fire-resistive barrier between the generator set
electrical arcs and switches and all other
and coach interior. Make sure all mounting screws,
sources of ignition well away. Keep a multi-
and brackets are secure and that all battery, AC out-
class ABC fire extinguisher handy.
put, control, exhaust and fuel connections are prop-
Disconnections er and in good repair. Perform the service checklist
before placing the generator set back in service
1. Disable the automatic generator set starting (Section 7. Service Checklist).
feature of an inverter-charger or other automat-
ic starting device and disconnect the battery Note: It is critical for good vibration isolation that the
cables from the battery (negative [−] first) to four bolt holes in the vehicle frame line up accurately
keep the generator set from starting while with the mounting holes in the generator set mount-
working on it. Then disconnect the battery ing brackets so that the vibration isolators do not
cables from the generator set. have to be bent to line up with the holes in the vehicle
frame.
2. Disconnect the remote control wiring harness
connector at the generator set. Secure the generator set to the vehicle structure
3. Disconnect the AC output leads at the genera- with four (4) Grade 5 bolts of at least 3/8 inch diame-
tor set terminals. ter.

4-1
 TORQUE TO 10 FT-LBS
(14 N-M)

TORQUE TO 14 FT-LBS
(19 N-M)

FIGURE 4-1. GENERATOR SET MOUNTING BRACKETS AND VIBRATION ISOLATORS

4-2
 REMOVING OUTER HOUSING internal AC and DC wiring. When reassembling the
outer housing, tighten the housing screws to 27 in−
Remove the outer housing panels (Figure 4-2) to
lbs (3 N−m).
service or replace the starter, muffler, inverter and

FIGURE 4-2. OUTER HOUSING

4-3
 INVERTER When remounting the inverter, tighten the isolator
mounting screws to 8 ft−lbs (11 N−m).
The Inverter (Figure 4-3) inverts the main 3-Phase
PMA (Permanent Magnet Alternator) output into
INTERNAL CONTROL PANEL
1-Phase, 60 Hz, 120 VAC output from the generator The internal control panel (Figure 4-3) is a connec-
set. It also provides all generator set control func- tion point for the internal generator set control cir-
tions. For connections see the wiring diagram on cuits. The 9-Pin connector is for B+ and engine cir-
Page A-1. cuits. The 10-Pin connector is for the Operator Pan-
el. The 6-Pin connector is for the PMA battery
The inverter has a microprocessor which monitors charging auxiliary winding and for communications
output power, engine speed, engine oil pressure, oil with the Inverter. For connections see the wiring dia-
temperature, Inverter temperature and ambient gram on Page A-1.
temperature. Through the remote Operator Panel, it
enables starting and stopping the generator set and The control panel has a 30 amp automotive-type
provides status, maintenance, warning and fault fuse to protect the control circuits if a component or
messages. See Section 5 . Troubleshooting. connector shorts to ground.

INVERTER

INTERNAL CONTROL
PANEL

30 AMP FUSE

FIGURE 4-3. INVERTER

4-4
 DC CABLES
Route and clamp the DC cables as shown (Figure
4-4). Torque the terminal nuts to 10 ft−lbs (14 N−m).

POSITIVE (+) ENGINE

BATTERY CABLE GROUND
TERMINAL

NEGATIVE (−)
BATTERY CABLE
TERMINAL
STARTER
SOLENOID

FIGURE 4-4. INTERNAL DC CABLES

4-5
 FUEL SYSTEM REMOVING ENGINE/PMA ASSEMBLY
Figure 4-5 illustrates the fuel delivery system (trans-
fer pump, filter and hoses). See the Engine Work- See Engine Workshop Manual 983−0504 for servic-
shop Manual 983−0504 for fuel injection system ing the engine—adjusting valve clearance (lash),
service. servicing the fuel injection system, replacing the
glow plug, overhauling the engine.
WARNING Diesel fuel is combustible and can
cause severe personal injury or death. Do not
smoke near fuel tanks or fuel-burning equip-
ment or in areas sharing ventilation with such Disassembly
equipment. Keep flames, sparks, pilot flames,
electrical arcs and switches and all other
sources of ignition well away. Keep a multi- To remove the engine/PMA assembly (Figure 4-5)
class ABC fire extinguisher handy. as an assembly:

Fuel Transfer Pump 1. Disconnect the DC cables (p. 4-5)

To test the fuel transfer pump, disconnect the fuel 2. Disconnect the fuel lines.
supply line at the engine and direct the end into a
1 gallon (4 liter) container. Press the Display ON 3. Remove the outer housing (p. 4-3).
button on the Operator Panel to prime fuel (five min-
utes). Press the Gen OFF button to stop priming be- 4. Remove the muffler.
fore the container fills up. Replace the pump if it
does not provide a steady flow of fuel after air has 5. Disconnect the AC wiring harnesses.
been bled from the system.
6. Remove the inner housing assembly.
Flow must be at least .4 pints (200mL)/minute.

Fuel Filter 7. Remove the Engine/PMA assembly from the

four vibration isolator mounts (Figure 4-6).
See REPLACING THE FUEL FILTER (Page 3-8).

Internal Fuel Hoses Reassembly

When replacing the internal fuel hoses, make sure
1. Tighten the engine mounting bracket bolts (to
they are re-clamped and tied so as not rub on or be
engine) to 14 ft−lbs (19 N−m).
pinched by adjacent components.

MUFFLER 2. Tighten the engine mounting isolator bolts (to

generator set base) to 10 ft−lbs (14 N−m).
Figure 4-5 illustrates the muffler assembly. When
reassembling the muffler: 3. Remount the muffler.
1. Tighten the exhaust clamp screws to 7.4 ft−lbs
(10 N−m). 4. Reconnect the fuel lines.

2. Tighten the exhaust flange nuts at the engine to 5. Tighten the engine harness connector screws
__ ft−lbs (__ N−m). Make sure to use a new to 10.6 in−lbs (1.2 N−m).
flange gasket.
3. Tighten the exhaust isolator screws to 13 ft−lbs 6. Tighten the housing screws to 27 in−lbs
(18 N−m). (3 N−m).

4-6
 MUFFLER
EXHAUST FLEXIBLE
CONNECTOR

ENGINE EXHAUST
FLANGE ADAPTOR
AND GASKET
INNER HOUSING
ASSEMBLY

FUEL FILTER

ENGINE / PMA
ASSEMBLY

FUEL PUMP

FIGURE 4-5. GENERATOR SET ASSEMBLY

4-7
 VIBRATION
ISOLATORS (4)

ENGINE
MOUNTING
BRACKET

FIGURE 4-6. ENGINE VIBRATION ISOLATORS

4-8
 PMA ance between pins 2 and 3. Replace the stator if the
winding is grounded or open or does not measure
The PMA (Permanent Magnet Alternator) is 0.3 ohms within 10 percent.
mounted on top of the vertical-shaft engine (Fig-
ure 4-7). The permanent magnets rotate around the Engine speed
outside of the stator.

The stator has a three-phase main winding and two To calculate engine speed, measure PMA Frequen-
single-phase auxiliary windings. For connections cy, HZ(60/9) = Engine RPM
see the wiring diagram on Page A-1.
Disassembly/Reassembly
PMA Tests
CAUTION Hitting the rotor or prying against it
Disconnect the 9-pin connector on the Inverter and to remove it can break the magnets inside.
measure main winding resistance between pins 1
and 2; 2 and 3; 3 and 1. Replace the stator if any
See Service Manual, Engine Workshop 938−0504
winding is grounded or open or does not measure
for disassembly/Reassembly instructions.
1.1 ohms within 10 percent.

With the 9-pin connector disconnected from on the TORQUE SPECIFICATIONS:

Inverter, measure auxiliary winding resistance be-
tween pins 4 and 9. Replace the stator if the winding SIZE GRADE N.m Ft−Lb
is grounded or open or does not measure 0.3 ohms M6 1.0 8.8 11 8
within 10 percent. M8 1.125 8.8 23 17
Disconnect the 6-pin connector from the Internal M10 1.5 8.8 52 39
Control Panel and measure auxiliary winding resist- M12 1.75 8.8 84 62

4-9
 OUTER FAN
(ENGINE COOLING)

INNER FAN
(PMA COOLING)

PMA ROTOR

PMA STATOR

FAN SHROUD

ENGINE

FIGURE 4-7. PMA

4-10
5. Troubleshooting
Note: Most generator set shutdowns and failures to MAINTENANCE MESSAGES
start can be avoided by performing periodic mainte-
nance on schedule (TABLE 3-1. PERIODIC MAINTE- OIL CHANGE / CHECK OIL LEVEL These mes-
NANCE SCHEDULE) and by making sure that the sages appear every time the generator set hour
generator set does not run out of fuel. In this regard it counter reaches preset oil check/change intervals
should also be noted that the vehicle manufacturer (change after first 20 hours and then every 250
has probably arranged the fuel tank dip tubes such hours). The generator set continues to run. Fill or
that the generator set will run out of fuel before the
change oil as necessary. The generator set must be
fuel gauge reads EMPTY, thus reserving fuel for the
propulsion engine.
running to reset the message. Hold START until the
message clears. If not reset, the message will re-
STATUS MESSAGES appear after an hour of running.
WARNING MESSAGES
The Operator Panel displays the following status
and periodic maintenance messages. Warning and SHORT CIRCUIT A connected appliance probably
Fault messages, once cleared, cannot be retrieved. has a short circuit. AC output voltage is turned off
To clear faults turn display off/on. but the engine is kept running to cool the generator
set. Disconnect all appliances, press STOP to stop
Note: Operator warning and fault messages, once the engine and then restart the generator set. Re-
cleared, cannot be retrieved. connect appliances one by one to find out which one
shorted and have it repaired or replaced.
GEN OFF Indicates that the generator set is off but
ready to start. FAULT MESSAGES

GEN ON Indicates that the generator set is run- OIL TEMP-PRESS

ning. Possible Cause: The engine lubricating oil temper-
ature is too high or the pressure is too low. The oil
GEN START If this message appears while press- pressure and temperature switches are connected
ing START, but the engine does not crank, check the in parallel. When the engine is at rest and cold, the
stop switch inside the generator set (p. 2-2) and pressure switch is closed and the temperature
push it on. switch is open.
GEN CAL This message appears during generator Diagnosis/Repair—Low Oil Pressure:
set start-up indicating that it is in calibration mode 1. Check Oil level and refill as necessary.
and not yet ready to produce AC output voltage.
Wait a few seconds. 2. The oil pressure switch is normally closed
(closes between 2.5 and 3.6 psi). Normal pres-
RESTART GEN? This message appears any time sure is 36 psi at 3000 RPM. With the engine
the generator set stops. Turn off and restart the gen- stopped, check for continuity to ground through
erator set. the oil pressure switch. Replace if open.
3. If the oil pressure switch is opening, verify the
GEN WAIT The generator set is delaying the next connections between the engine harness and
start attempt to allow the starter motor to cool down. internal control board. Check for shorts to
Or, more time is being allowed for engine preheating ground. To check if the switch is opening re-
because the ambient temperature is below freezing. move wire No. 4 (black) from the engine har-
Try restarting when the message turns off. ness connector on the engine side of the con-
nector. Start the generator set and verify that
LOW BATTERY Battery voltage is below the mini- the switch is opening. If this test is performed
mum value (9 VDC) necessary to start the generator without removing the wire from the harness, the
set. Check battery connections and recharge or re- test meter may provide enough of a ground
place the battery. path to shut down the generator set.

5-1
 4. If the switch does not open, one of 3 conditions will likely occur when attempting to start the
exists: a) short to ground in the engine harness, generator set.
b) faulty oil pressure switch, c) low engine oil 2. Without power from the PMA auxiliary windings
pressure. Remove the oil pressure switch and AC3 and AC4, the inverter will not be able to
test operation using a hand pump to apply ap- communicate with the Operator Panel. If the
propriate pressure. Check harness for shorts to output frequency detected by the inverter is too
ground. Replace wiring and or switch as neces- high (engine speed greater than 4200rpm) the
sary. If the oil pressure circuit is okay, check the inverter will shut down the generator set.
high oil temperature protection circuit. See PMA information in section 4−9 for engine
speed calculation.
Diagnosis/Repair—High Oil Temperature:
3. Faulty inverter.
1. Check for and remove blockages in the cooling
air inlets and outlets. CAUTION Always perform stator check before
2. Apply standard derates for elevation and tem- replacing the invertor. Failure to do so will result
perature and reduce loads as needed. in damage to the inverter.

3. The oil temperature switch is normally open Diagnosis/Repair:

(cold) and closes at 220 C (428 F). 1. Disconnect the vehicle AC wiring from the gen-
4. Verify that the rise over ambient does not ex- erator set and connect the generator set to a
ceed 15 F (See Hot air recirculation test in the load bank. If the problem goes away check the
Installation Manual). vehicle AC wiring for shorts. Shorts to ground
can cause an inverter communications fault.
5. If engine appears to be cooling properly, re-
move the orange wire from the 9 pin connector 2. Check for open wiring, shorts to ground, and
on the internal control panel and start the gen- bad crimps at the 2-pin connector on the invert-
erator set. Once running, check continuity to er and at Pins 1 and 6 of the 6-pin connector on
ground through this wire. There should be con- the internal control board.
tinuity while the engine is at rest through the oil 3. Check for open wiring to ground and bad
pressure switch but not while the generator set crimps at Pin 5 of the 6-pin connector on the in-
is running. If the low oil pressure protection cir- ternal control board.
cuit is okay, a short to ground in this test indi-
4. Check for open wiring, shorts to ground, and
cates a faulty high oil temperature protection
bad crimps at Pins 1 and 4 of the 12-pin con-
circuit.
nector on the Operator Panel and for good con-
6. f there is a short to ground when the generator nections at pins 7 and 10 of the 10-pin connec-
set is running but engine temperature is rela- tor on the internal control board.
tively cool, remove the temperature switch and
5. Check for open wiring, shorts to ground, and
test using a hot plate to heat the switch to clos-
bad crimps at Pins 4 and 9 of the 9-pin connec-
ing temperature. Replace the temperature
tor on the inverter.
switch if it does not close.
6. Check PMA winding connections to the internal
7. Check wiring for shorts to ground and repair as control board and inverter. Refer to PMA tests
necessary. (p. 4-9) and replace PMA stator if necessary.
8. If the low oil pressure and high oil temperature 7. Replace a faulty inverter.
protection circuits are okay, service the engine
lubricating oil pressure system. Refer to Engine CAUTION Always perform stator check before
Workshop Manual 983−0504. replacing the invertor. Failure to do so will result
in damage to the inverter.
GENERATOR ALERT
OVER TEMPERATURE (INVERTER)
Possible Cause There are three possible causes:
Possible Cause Inverter temperature detected to
1. The Operator Panel in the vehicle must be able be over 70 C.
to communicate with the inverter in the genera-
tor set. If communication is interrupted this fault Diagnosis/Repair:

5-2
 1. Reduce loads. 2. Reduce Loads: Disconnect AC output leads
and connect to load bank. Test performance.
2. Verify that the inverter heat sink is clean and
that there is no air flow restriction or hot air recir- 3. Check Fuel Flow: Verify fuel flow from lift pump
culation. it should be approximately 0.4 pints/min-
ute(200 ml/minute) If flow is low check for
3. After allowing generator and inverter too cool,
kinked hoses and replace fuel filter as needed.
start and run the generator set with no load. If
it still shuts down on OVER TEMPERATURE, 4. Check air flow (intake,exhaust) for restrictions:
replace the inverter. Remove exhaust and test, (spark arrestor
clean out may be needed).
CAUTION Always perform stator check before 5. Verify that the stop solenoid is operating cor-
replacing the invertor. Failure to do so will result rectly. Replace the solenoid if it does not pull in
in damage to the inverter. when 12 VDC is applied to its terminals.
OVERLOAD 6. Check the PMA winding connections at the in-
ternal control board and inverter. Refer to PMA
Possible Cause Too many applications are con- tests (p. 4-9). Replace PMA stator if necessary.
nected, or the inverter is defective. 7. The engine “wet-stacked” when run under no
load. Run under approximately 3/4 rated load
Diagnosis/Repair: for approximately 30 minutes. If the problem
1. Measure current draw. If it is greater than 32 persists, go to Step 8.
amps, reduce the number of appliances con- 8. The injector is partially blocked. Check the
nected in the coach and wait a few minutes for spray pattern and replace as necessary. Refer
generator set to cool down. Press STOP to stop to Engine Workshop Manual 983−0504.
engine and restart the generator set.
9. The injector popping pressure is too Low.
2. If the generator set shuts down on ’Overload’ Check the popping pressure and replace as
condition, disconnect it from the coach and necessary. Refer to Engine Workshop Manual
bench-test with a load-bank. If the generator 983−0504.
set runs fine without shutting down, then the
problem likely exists within vehicle wiring and/ 10. The engine is worn. Refer to Engine Workshop
or appliances. In the event that it shuts down Manual 983−0504.
with no load connected, perform checks in Step
3. SYMPTOM DIAGNOSTICS
3. Ensure stator is not damaged and has no DEAD OPERATOR PANEL
shorts internally or to Ground on all Main and
Auxiliary Windings. Test winding insulation re- Possible Cause/Diagnosis/Repair
sistance with a Megger. Replace state if neces-
1. Verify that the battery is fully charged and that
sary. If the stator is good, replace the inverter.
the connections are clean and tight.
CAUTION Always perform stator check before 2. Check for 12 VDC at Pin 12 of the 12-pin con-
replacing the invertor. Failure to do so will result nector on the Operator Panel and for a good
in damage to the inverter. ground at Pin 1. (The Operator Panel requires
at least 9 volts to function.) If there is no voltage:
LOW ENGINE POWER A. Replace the 30 amp fuse on the internal
control panel, if blown.
Possible Cause Engine speed is below 2300 rpm
B. Check for 12 VDC at Pin 3 of the 10-pin
Diagnosis/Repair: connector on the internal control panel and
1. Check that the engine stop lever is in its vertical for a good ground at Pin 10.
(run) position (Figure 5-1). Refer to Engine C. Check for 12 VDC at Pins 2, 3 and 6 of the
Workshop Manual 983−0504 if the lever does 9-pin connector on the internal control
not return to the run position after it has been panel and for a good ground at Pin 5 of the
pushed to stop the engine. 6-pin connector.

5-3
 D. Repair wiring and connectors as neces- 10. The injection pump is stuck. Remove the high
sary. pressure injector line and crank the engine.
Watch for fuel at delivery valve. Refer to Engine
3. Replace the internal control board if there is 12
Workshop Manual 983−0504
VDC at at Pins 2, 3 and 6 of the 9-pin connector
but 9 VDC or less at Pin 3 of the 10-pin connec- 11. Engine compression is low—blown head gas-
tor. ket, bad injector seal, worn engine. Refer to En-
gine Workshop Manual 983−0504.
4. Replace the Operator Panel if it does not wake
up when if there is 12 VDC at Pin 12 of the ENGINE SPITS/SPUTTERS/EXHAUSTS WHITE
12-pin connector and a good ground at Pin 1. SMOKE

ENGINE CRANKS BUT DOES NOT START Possible Cause/Diagnosis/Repair

1. Air in fuel system: Prime fuel system by turning
Note: The generator will make up to three start at-
tempts, cranking each time for 5 seconds and paus- on the display, lift pump should run for 5 min-
ing for 2 seconds if necessary before the next crank. utes to prime system. If problem goes away
Gen Wait should appear on the display. check for air leaks with soapy water at fittings
and hoses.
Possible Cause/Diagnosis/Repair 2. Bad Check Valve in return fuel line: Block of re-
1. Clear the Gen Wait message from the Operator turn line and test run. If problem goes away re-
Panel by cycling it off and on. Try starting again. place check valve.
2. Check the fuel level and fill as necessary. ENGINE EXHAUSTS BLACK SMOKE
3. Press the stop switch (p. 2-2) if it is not in its “1” Possible Cause/Diagnosis/Repair
position.
1. The injector is partially blocked. Check the
4. Replace the fuel if it is not of the specified grade spray pattern and replace as necessary. Refer
or suitable for the ambient temperature (p 2-1). to Engine Workshop Manual 983−0504.
5. Check Fuel flow from lift pump, should be 2. The injector popping pressure is too Low.
approximately 0.4 pints/minute (200 ml/min- Check the popping pressure and replace as
ute). Look for kinked hoses and replace fuel fil- necessary. Refer to Engine Workshop Manual
ter as need. 983−0504.
6. Verify that the fuel solenoid is getting 12V DC
ENGINE WON’T STOP
and clicks open when energized.
7. The cam to crank timing is off. Check Timing. Possible Cause/Diagnosis/Repair
Refer to Engine Workshop Manual 983−0504. 1. Stop the engine by pushing the engine stop le-
8. Valves not set properly: Check Valve lash. Re- ver (Figure 5-1) all the way to the left.
fer to Engine Workshop Manual 983−0504. 2. Remove the fuel solenoid and apply 12V DC.
9. The injector nozzle is blocked or locked. Re- Replace the solenoid if it does not function
move the injector and check popping pressure (click open).
and spray pattern. Refer to Engine Workshop 3. Contact HATZ to readjust the idle adjustment
Manual 983−0504. screw.

5-4
 SERVICE SCREENS
Accessing Service Screens
Generator service information can be accessed as
follows:
1. Press Gen OFF
2. Hold down the START button and Display ON
together.
3. Release both buttons when RV QD 3200 is dis-
played.
4. IMMEDIATELY press the START button 3 time.
GEN OFF should be displayed. (Restart the
procedure if the generator set tries to start.)
5. Press the START button again to start the gen-
erator set.
6. Once the generator set has started, press the
START button to view the service screens.
7. Use the START button to navigate through the
service screens.

Service Information
The following generator service information is avail-
able on the service screens:
ENGINE STOP
LEVER 1. Battery voltage
2. Generator status
3. Inverter output AC voltage
4. Generator set running hours
5. Software version number
6. Load current draw
FIGURE 5-1. ENGINE STOP LEVER
7. Load kW

5-5
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

5-6
6. Specifications

GENSET CONTROL: Integrated Microprocessor-Based Engine and Generator Controller and AC Output In-
verter
GENERATOR: Three-Phase, Permanent Magnet, 3600 RPM
Power (@1.0 power factor) See Nameplate
Voltage 120
Frequency 60 Hz
Number of Phases 1
Current 26.7 amps
FUEL CONSUMPTION:
@ 1 kW 0.20 gph (0.76 lph)
@ 2 kW 0.27 gph (1.03 lph)
@ 3 kW 0.36 gph (1.37 lph)
@ 3.5 kW 0.38 gph (1.44 lph)
ENGINE: Single-Cylinder, Direct-Injection, Air-Cooled, 4-Stroke Diesel
Bore 3.15 in (80 mm)
Stroke 2.72 in (69 mm)
Displacement 21 in3 (347 cc)
Compression Ratio 1:22
Fuel Injection Timing (BTDC) 16
Fuel Nozzle Injection Pressure 2900174 psi (20012 bar)
Cylinder Compression Test 290 to 319 psi (20 to 22 bar)
Valve Lash: Intake & Exhaust (cold) 0.004 in (0.1 mm)
Oil Capacity 1.1 quart (1.1 liter)
DC SYSTEM:
Nominal Battery Voltage 12 volts
Minimum Battery Capacity 475 amps down to 0 F (−17 C)
CCA (Cold Cranking Amps) 650 amps down to −20 F (−29 C)
WEIGHT (WET): 205 lbs (93 kg)
SIZE (L x W x H): 30.17 x 17.3 x 18.02 in (766.4 x 439.4 x 457.7 cm)
SOUND LEVEL: 68 dB(A) @ 10 ft (3 meters)
quality. We therefore recommend a minimum
engine load of 15%.
LOAD ON ENGINE
 If operated at such low loads, it is best to oper-
 Operating the engine for a lengthy period off− ate the engine at a significantly higher load for
load or at very low loads can affect its running a short period before switching it off.

6-1
THIS PAGE LEFT INTENTIONALLY BLANK

6-2
7. Service Checklist
After servicing, inspect and test the installation to nections, welds, gaskets and joints. Also make sure
confirm that the genset will operate as intended. the exhaust pipe is not overheating adjacent materi-
Check each of the areas described below before als or equipment. Do not run the genset until all ex-
putting the genset into service. haust leaks have been repaired.

Housing WARNING Exhaust gas is deadly. The exhaust

system must not leak and must discharge all ex-
Check to see that all housing panels and access haust away from the vehicle. Do not run the gen-
covers are in place and secure. set until the exhaust leaks have been repaired.

Mounting The exhaust tailpipe must be supported by a

hanger near the vehicle perimeter and terminate
Examine all mounting bolts and supporting mem- at least 1 inch outside the perimeter and at least
bers to verify that the genset is properly mounted. 1 foot from doors and windows.
All fasteners should be tightened securely to pre-
vent them from working loose when subjected to Fuel System
vibration.
While the genset is running, inspect the fuel supply
Lubrication and return lines, filter and fittings for leaks. Check
flexible sections for cuts, cracks and abrasions and
If the engine oil was drained, refill as required. make sure they are not rubbing against anything
that could cause leakage. Repair all fuel leaks im-
Wiring mediately.

Verify that all wiring connections are tight and WARNING Diesel fuel is combustible. Leaking
installed properly. Check each of these connec- fuel could lead to fire and to severe personal in-
tions: jury or death. Repair fuel leaks immediately.
 Load wires Control
 Control wires
Stop and start the genset several times at the Oper-
 Ground straps ator Panel in the vehicle to verify connections and
 Battery cables proper operation.

Output Check Mechanical

Apply a full load to make sure the genset can pro- Stop the genset and inspect it for leaking gaskets,
duce rated output. Use a load test panel to apply a loose fasteners, damaged components and inter-
progressively greater load until full load is reached. ference with other equipment. Repair as necessary.
Inspect the generator compartment and verify that
Exhaust System there are no breaks or openings in the vapor-resist-
ant barrier that separates the compartment from the
While the genset is running inspect the entire ex- vehicle interior. Seal openings as necessary. Make
haust system. Look and listen for leaks at all con- sure that all soundproofing material is in place.

7-1
THIS PAGE LEFT INTENTIONALLY BLANK

7-2
 Socket connector
22 7 4 3 2 24

6 5 4 3 2 1

Pin connector
1 0 − − 5 6

1 2 3 4 5 6

Note for Specs A & B: The

PreGlow heater is disconnected
at Pin 9 of the 9-Pin connector
on the Internal Control Panel.

WIRING DIAGRAM

A-1
Cummins Power Generation
1400 73rd Ave. NE
Minneapolis, MN 55432 USA
Phone 1 763 574 5000
Toll-free 1 800 888 6626
Fax 1 763 574 5298
Email [email protected]
www.cumminspower.com
CumminsR, the “C” logo, and “Our energy working for you.”
are trademarks of Cummins Inc.
E2010 Cummins Power Generation, Inc. All rights reserved.